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As the demand for high-performance dissimilar material joining continues to increase in fields such as aerospace, biomedical engineering, and electronics, the welding technology of dissimilar materials has become a focus of research. However, due to the differences in material properties, particularly in the welding between metals and non-metals, numerous challenges arise. The formation and quality of the weld seam are strongly influenced by laser process parameters. In this study, successful welding of high-borosilicate glass to a TC4 titanium alloy, which was treated with high-temperature oxidation, was achieved using a millisecond pulsed laser. A series of process parameter comparison experiments were designed, and the laser welding behavior of the titanium alloy and glass under different process parameters was investigated using scanning electron microscopy (SEM) and a universal testing machine as the primary analysis and testing equipment. The results revealed that changes in process parameters significantly affect the energy input and accumulation during the welding process. The maximum joint strength of 60.67 N was obtained at a laser power of 180 W, a welding speed of 3 mm/s, a defocus distance of 0 mm, and a frequency of 10 Hz. Under the action of the laser, the two materials mixed and penetrated into the molten pool, thus achieving a connection. A phase, Ti5Si3, was detected at the fracture site, indicating that both mechanical bonding and chemical bonding reactions occurred between the high-borosilicate glass and the TC4 titanium alloy during the laser welding process. [ABSTRACT FROM AUTHOR]

• A proposal is made to conduct anodic oxidation treatment on TC4 titanium alloy to prepare an oxide film on its surface as a buffering layer for glass-to-metal welding. • The shear force of glass/metal welded joints shows a decreasing trend with increasing thickness of the anodic oxide film. • The surface anodic oxide film of TC4 titanium alloy exhibits high roughness and numerous internal pores, which are not conducive to the bonding of the two materials. • Under the action of a laser beam, glass and metal undergo penetration mixing within the molten pool to form a bond. This study investigates the influence of the thickness of the oxide film formed on the surface of TC4 titanium alloy after anodization on the laser transmission welding between the titanium alloy and high borosilicate glass. The effects of oxidation time on the morphology and thickness of the oxide film were examined, and the elemental and phase composition of the oxide film were characterized. The differences in welding strength, weld morphology, and fracture surface between the titanium alloy before and after oxidation treatment and high borosilicate glass welding were compared, and analyzed the welding seam formation mechanism. Within our research scope, the results indicate that with an increase in oxide film thickness, the surface roughness gradually increases and the internal voids gradually increase, resulting in a decrease trend in the bonding strength of the welded joints with the increase in oxide film thickness. The interpenetrating structure formed by the mutual infiltration of glass and metal in the molten pool is identified as the main reason for their connection. [ABSTRACT FROM AUTHOR]